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LEARNING MATERIAL
Farm Machine and Equipment Maintenance Worker
Index:
1) Introduction to the FLP Farm Machine and Equipment
Maintenance Worker.
2) Occupational Health and Safety.
3) Environmental care and waste disposal.
4) Use of tools and tool care.
5) Lifting equipment and aids.
6) Measuring instruments and units.
7) Fasteners
8) Metalwork tools and equipment and their use.
9) Basic Hand Skills.
10) Gas cutting and welding.
11) Arc welding.
12) Identify farm machines and equipment.
13) Routine Maintenance.
1) Introduction to the FLP Farm Machine and Equipment maintenance Worker.
This foundational learning program is intended to
Occupational Health and Safety.
INDEX
1. INTRODUCTION TO OCCUPATIONAL HEALTH AND SAFETY ACT
2. DEFINITIONS
3. DUTIES IN TERMS OF THE ACT
4. BASIC CRITERIA OF THE HEALTH AND SAFETY SYSTEM
5. COMPLIANCE WITH THE SET STANDARD
6. OCCUPATIONAL HEALTH
7. ERGONOMICS
8. MACHINE GUARDS
9. LOCK-OUTS
10. LADDER AND SCAFFOLDS
11. POLLUTION
12. OFFENCES AND PENALTIES
13. OFF THE JOB, HYGIENE, HEALTH AND SAFETY
1. INTRODUCTION TO THE OCCUPATIONAL HEALTH AND SAFETY ACT
It is a well established principle in our law that an employee has an implicit right to work in a safe working environment. Conversely, the employer has an obligation to ensure that his employees are not exposed to safety hazards. Infringements constitute criminal offences.
The legislation was at first unsophisticated and very much prescriptive. The Act (commonly known as Factories Act), was largely ineffective as the penalties for non-compliance were marginal and responsibility vested in the so-called, factory engineer. These inefficiencies resulted in promulgation of the Machinery and Occupational Safety Act No. 6 of 1983 (MOSACT) which repealed the old Factories Act.
The MOSACT initially was less prescriptive and made provision for more serious penalties. As time went by, new regulations were issued in terms of the MOSACT and this Act evolved into a very complex legislative framework. The MOSACT further made management responsible for employees safety and the Chief Executive Officer became the focus point of the employers safety program. This position was re-enforced by the 1991 amendment to the Machinery and Occupational Safety Act.
It was clear that the MOSACT was more effective than the Factories Act, but it still did not address Occupational Health issues. The Minister of Labour realised that health is as important as safety and accordingly consulted with various Trade Unions, Employer Organisations, State Departments and other relevant entities with the view to incorporating health into safety legislation. This led to the publishing of various draft bills on Occupational Health and Safety which culminated in the promulgation of the Occupational Health and Safety Act No. 85 of 1993 (OHS-Act).
The OHS-Act is regarded, generally, as very progressive and in touch with the needs of both the employer and his employees. For the first time, it is accepted that Occupational Health and Safety should be addressed by both the employer and his employees. Employees are now part of the Occupational Health and Safety management program and they are responsible for ensuring that they participate in the advancement of Occupational Health and Safety of all employees and non-employees who may be affected by their work activities.
The Act caters for constant interaction between employees and management with the view to ensuring a high standard of Occupational Health and Safety at the workplace.
The OHS-Act further makes provision for an obligation on behalf of management and employees to ensure that any other persons whose health and safety may be affected by the employers activities are not endangered. As you will note, the Act has extended both the employer and his employees duties to such an extent that they can no longer be oblivious to Occupational Health and Safety in the workplace.
2. DEFINITIONS
Incident
Unplanned, uncontrolled and undesired event caused by an unsafe act and/or unsafe condition, which results in any loss or potential loss.
Safe
Free from hazard
Hazard
A source of/or exposure to danger
Danger
Anything which may cause injury or damage to person or property
Unsafe act
Any deviation from a set working standard
Unsafe condition
Any deviation from a mechanical and/or environmental set standard
Employer
Any person who employs or provides work for any person and remunerates that person
Employee
Any person who is employed by or works for an employer who receives or is entitled to receive any remuneration or who works under the direction or supervision of an employer or any other person
Workplace
Any place where work is performed
Employment
Employment or employed as an employee
First aid injury
Superficial injury which was sustained that does not need medical attention by a qualified doctor or hospital and the person is able to carry on with his work after the qualified first aider attended to the injury
More than first aid
Any injury that requires the attention of a medical practitioner because the person is not able to continue with his work due to the injury
3. DUTIES IN TERMS OF THE ACT
SECTION 16
EXECUTUVE APPOINTMENT
The Chief Executive Officer, is overall responsible and accountable for the health and safety of all employees under his direction
He may delegate duties and responsibilities to other members of his staff under, and according to Section 16 of the OHS-Act
The above people in turn may on CEOs instruction delegate responsibilities to others under their direction, but the CEO remains accountable for the program status. This may extend to appointments in terms of Section 16 of the Act, and would be determined by the application of the term reasonably practicable.
SECTION 8
GENERAL DUTIES OF EMPLOYERS REGARDING THE HEALTH AND SAFETY OF THEIR EMPLOYEES
What are the general duties of employers to the employees (including Health and Safety Representative)?
Every employer shall provide and maintain, as far as is reasonably practical, a working environment that is safe and without risk to the health and safety of his employees. To achieve this the employer has to do the following:
Provide a plant, machinery and working systems that are safe and without risk to the health of employees
Take steps to eliminate or mitigate hazards to the safety and health of employees before resorting to personal protective equipment
Ensure what is necessary to provide for safety and absence of risk to the health of employees when using, handling, storing, etc. of articles or substances
Determine what measures should be taken in order to protect the health and safety of persons in a workplace
Provide information, instructions, training and supervision that may be necessary to ensure the health and safety of his employees
Prevent any employee from performing hazardous work is the prescribed measures have not been taken
Take measures to ensure that every person in his employ conforms to the relevant requirements of the legislation
Enforce the measures that may be necessary in the interest of health and safety
Ensure that those in a supervisory capacity are trained to understand the hazards of the task in hand an that they have the authority to ensure that adequate measures are taken and implemented
Ensure that employees know and understand what is expected of them and why as well as what actions they should take while carrying out their duties and tasks (e.g. operating procedures)
SECTION 9
DUTIES OF EMPLOYER TO PERSONS OTHER THAN THEIR EMPLOYEES
Conduct the undertaking in such a manner as to ensure, as far as is reasonably practical, that all persons other than employees are not exposed to hazards to health and safety.
Elements of the abovementioned to be discussed:
This section relates to all persons, and makes no distinctions between persons entering the premises with, or without permission, or with, or without being accompanied by an employee. The aspects pertaining to visitors, contractors, casual employees and trespassers, will be addressed at a later stage during this course
This section is wide enough to include neighbours of the site as well as persons residing some distance away from the site, who are able to prove that the activities of the site are adversely affecting their health and safety
The environmental legislation has assumed greater importance during the last decade in South Africa, to such an extent that the environment in itself, may be regarded as a legal person in its own right. This aspect carries considerable weight, due to the fact that should any person be able to indicate that the activities of an organisation, adversely affects the environment in any way, the organisation would have to disprove this
It has become normal practice in industry, to require visitors and contractors to sign an indemnity clause, prior to entering the site. In terms of such indemnities, the visitor or contractor undertakes to be responsible for their own health and safety. Considering that Section 9 does not provide an option to exclude the responsibility brought about by the section, as do sections 10 and 37, the contention has been made that such indemnity clauses are contrary to the legislation and therefore, invalid. This aspect will be discussed in more detail, at a later stage.
Under the terms of current legislation, the employer (CEO) is responsible to making sure that any contractors and their employees, who are working on the premises carry out all their tasks in compliance with legislation.
Contractors must be informed of any hazards which may be in the area that they are in. They must be given training on any hazards on the site. They must also have and use all the necessary PPE and any other safety equipment to prevent exposure to themselves and/or anyone else.
It is best to have a written agreement drawn up so that both parties know what is required. All hazards have been identified and appropriate steps taken to prevent any incident.
SECTION 14 & 15
WHAT ARE THE GENERAL DUTIES OF EMPLOYEES AT WORK?
You should take care not to harm yourself or other people around you or interfere with their safety and health
Co-operate with your employer or other persons on the premises to ensure that all comply with their duties or legal requirements
Carry out all health and safety related instructions given to you and obey the health and safety rules and procedures laid down for the workplace or task
Report any hazardous situations or conditions to your Health and Safety Representative or employer
Report any incident which may affect your health and safety to the Health and Safety Representative for your area or to the employer before the end of the shift
WHAT ARE THE GENERAL DUTIES OF EMPLOYERS TO THEIR HEALTH AND SAFETY REPRESENTATIVES?
The employer must allow time during working hours for the Health and Safety Representative to inspect the workplace. The employer must also provide assistance and training that may be required by the Health and Safety Representative to carry out his functions successfully
It is important that the employer view the Health and Safety Representative as an important part of the team in all efforts to create and maintain a safe workplace which is free of risk to health and safety.
Where activities could create a risk to the safety and health of employees, the employer shall keep the Health and Safety Representative for that are informed of the actions taken to prevent exposure to the hazard. He must minimize such exposure, and keep Health and Safety Representatives informed of the occupational hygiene programme, as well as any biological monitoring and medical surveillance necessary.
The employer has to inform the involved Health and Safety Representative beforehand of inspections, investigations or formal enquiries planned by inspectors. The employer also has to inform the Health and Safety Representative concerned of the occurrence of an incident/accident in his section of the workplace as soon as possible. The employer may suppose that the Health and Safety Representative is aware of this incident/accident, but it still remains his responsibility to ensure that the Health and Safety Representative is officially informed of such an accident/incident.
SECTION 17
FUNCTIONS OF THE SAFETY HEALTH AND ENVIRONMENTAL REPRESENTATIVES
What are the functions of Health and Safety Representatives?
A Health and Safety Representative may perform the following functions in respect of the workplace or section of the workplace for which he has been designated, namely:
Examine the causes of incidents and accidents at the workplace
Carry our inspections of the workplace within scope of authority including inspections of the plant, machinery, health and safety equipment, any article or any substance at the workplace with a view to protecting the health and safety of employees
Identify hazards and deviations that may cause incidents at the workplace
Investigate complaints by employees relating to the employees health and safety at work
Make representations to the Health and Safety Committee or the employer on matters affecting the health and safety of employees at the workplace as well as matters causing incidents and accidents
Review the effectiveness of health and safety measures at the workplace
Participate in consultations with inspectors at the workplace to accompany Inspectors on inspections of the workplace (Remember that Health and Safety Representatives have been informed of visits by Inspectors to the are for which they have been appointed)
In his capacity as a Health and Safety Representative attend meetings of the Health and Safety Committee of which he is a member
Further to the above, a Health and Safety Representative may, in respect of the workplace or section of a workplace for which he has been appointed, perform the following functions:
Visit the site of an incident/accident and attend any inspections
Attend any investigation of formal inquiry
In so far as is reasonably necessary to perform his function, inspect any documents which the employer is required to keep, concerning the health and safety of employees in terms of legislation
With the approval of the employer be accompanied by a technical advisor on any inspection
Participate in any internal health and safety audit
We are going to have a more detailed look at two of the major functions of a Health and Safety Representative:
Accident/incident investigation
Inspections of the workplace or section of the workplace for which the Health and Safety Representative is designated
SECTION 19
FUNCTIONS OF THE SAFET, HEALTH AND ENVIRONMENTAL COMMITTEE
What is the function of a Health and Safety Committee?
A Health and Safety Committee has the task of noting the remedial action required by the employer arising out of reports received from the Health and Safety Representative. The Committee may make further recommendations to the employer regarding any health and safety hazards at the workplace. The Health and Safety Committee also has the task of noting the action taken by the employer to prevent a recurrence of accidents and incidents and may report any incident that occurred at the workplace to an Inspector. Furthermore, a Health and Safety Committee must keep a record of all recommendations made to employers or Inspectors on Health and Safety matters.
Does a Health and Safety Committee have to keep a record of proceedings?
It is legislated that the Health and Safety Committee keep the minutes of the proceedings of all meetings. These minutes should be signed by the employer indicating the steps that are to be taken to implement recommendations made by the Committee on health and safety matters at the workplace or a section of the workplace.
What procedures are followed at a Health and Safety Committee meeting?
The committee determines the procedures followed, but the steps indicated on the minutes serve as an example of procedures, which could be followed.
4. BASIC CRITERIA OF THE HEALTH AND SAFETY SYSTEM
What is an accident?
An accident is an unplanned and undesired event, mainly caused by human error / inefficiencies and/or high risk conditions that result in or have the potential for physical harm to persons and/or damage to property and/or business interruption.
Why should accidents/incidents be investigated?
Because it is important to arrive at some definite conclusion on how to prevent similar accidents/incidents in the future. Accidents/incidents investigation is thus about fact finding and not fault finding and the ultimate objective of accident investigations is to prevent similar occurrences in future.
What is an injury?
Any damaging physical force which applied to the body which leaves the person harmed or weakened in some way.
What is occupational illness?
A state where the systems or organs (liver, lungs, etc.) of the body are affected by substances, so that they do not function in a balanced and normal way.
What is occupational disease?
A physical condition which has specific signs and symptoms caused by exposure to substances in the workplace, and which is limited to and effects a certain part of the body.
What are the basic caused of incidents?
Personal factors
lack of knowledge, skill or both
physical or mental incompatibility
improper attitude or lack of motivation
Job factors
unsafe physical environment
inadequate work standards
What are unsafe acts?
Unsafe acts may motivate an action, which could result in injury, illness, disease or damage.
What are human errors / inefficiencies? (These cause 88% of all accidents)
Working at unsafe speeds
A forklift driver, in a hurry to deliver a pallet load of tin plates to the production area before lunch time, ignored the prescribed speed limit of walking pace when transporting a load. Whilst negotiating a right-angled turn, the load of plates slid from the pallet and skidded across the floor. The resulting scratch marks on the tin plated made them unsuitable for the intended product.
Working without authority
A machine operator at a printing works arrived early for work one morning. Without following the correct procedures he decided to clean the print rolls on one of the machines. Running the machine at high speed he commenced cleaning the rolls with a rag. The rag became between the rolls, pulling the mans hand and arm into the machine, resulting in his arm being torn off at the shoulder.
Failure to secure machinery and material
A worker cleaning an empty mixing drum of a concrete batching plat failed to follow WSWPs and isolate and lock-out. An operator inadvertently activated the mixing drum when commencing the next batch. The worker in the empty drum lost his life.
Rendering safety devices inoperative
A worker operating a two-hand controlled punch-press found that he could speed up the production rate by securing the one lever with a piece of string, feeding the press with his left hand whilst activating the press with the right hand lever only. Establishing a rhythm, he activated the press too soon, which did not allow sufficient time for his left hand to clear the point of operation. Four fingers were amputated.
Arranging or placing objects unsafely
To avoid the time consumed in building and breaking down stacks of bags of mealies at an animal feed mill, the bags were stacked without making use of the bonding method. Whilst breaking down a stack, the entire side of the stack collapsed onto several workers who suffered broken arms and legs.
Fooling, teasing, abusing workmates
A group of workers, fooling with a compressed air hose, blew compressed air into a colleagues rectum. This resulted in the rapture of his intestines. He subsequently died.
Using equipment unsafely or limbs instead of equipment supplied
In spiting a board on a circular saw the operator suffered the loss of his thumb. Instead of using the push-stick that had been provided he pushed the board past the saw with his hand. He had been performing similar operations at an average of twenty times a day for three months during which time he sustained many minor cuts and hundreds of close shaves.
Adjusting or working on moving machinery
A fitter decided to adjust the tension on a portable conveyer belt whilst the belt was in motion. His arm became trapped between the belt and the head pulley. This resulted in his arm being amputated at the shoulder.
Taking chances
Instead of walking around the factory premises to enter via the authorised entrance, a worker took the chance of illegally crossing a railway line to use an unauthorised entrance. He was struck by an oncoming train and killed.
Taking up unsafe positions
A lift serviceman sat on the edge of the landing with his legs dangling into the lift well. The lift, operated by his assistant without him being aware of its descent. Both his legs were severed.
Failure to use safety equipment or to wear protective apparel
A worker, not wearing the breathing apparatus provided, entered a wine maturation vat to clean out the dregs. He was overcome by fumes and lost his life.
What are unsafe conditions? (Engineering factors)
Any variation from accepted safety standards, which may be the cause of incidents. Some examples are listed below:
What are high risk conditions? (These cause 10% of all accidents)
Any physical condition which is a departure from accepted safety standards which, if left uncorrected, may be the cause of an accident/incident resulting in damage and/or injury.
Unsafe construction
A wooden ladder with knots in the rungs was used. The rungs broke when a builders assistant was climbing the ladder carrying a bucket filled with bricks.
Disorder and hazard planning (inadequate planning)
A conveyer belt was installed in the centre of the work area, without giving consideration as to how workers would cross from one side of the work area to the other. A worker lost his balance, fell and broke an arm.
Lack of machine or other guards
Many production machines are not provided with suitable guarding. Serious accidents could result.
Defective working conditions, such as rough, sharp or slippery surfaces
One of the major causes of falls in hotels for instance, is that floors are not constructed to the same level. Small differences in floor levels are not readily noticed and are tripping hazards.
Inadequate guarding
Large openings in the metal used for a machine guard, allowed an operators finger to extend through the guard. It was amputated by a V-belt running over a pulley.
Poor factory layout with inadequate or poorly marked walkways and exists
In a workshop where walkways had not been marked out on the floor, workers stacked material and equipment in any open space they could find, thereby forcing workers to either climb over the material or brush past dangerous machines in operation. This unsafe condition was the cause of a worker passing to close to a milling machine and being struck in the eye by a piece of swarf.
Overcrowding in workshops
Too many machines in a workshop limit the free space required around machinery. These conditions often lead to accidents/incidents which result in damage and/or injuries.
No personal protective equipment
People who do not wear suitable PPE may suffer injury, illness of disease
Unsafe ventilation
In areas where volatile flammable liquids are used, ventilation should be sufficient to either remove or dilute the air/vapour mixture to avoid ignition. This will help to prevent fires and explosions.
Unsafe lighting
Lighting in passageways and on stairway needs to be of correct intensity so that protrusions and tripping hazards are illuminated adequately. This is very important in emergencies. All lighting must comply with legal standards.
Storing of hazardous substances
A woman farm worker sent her small son to fetch some mealie meal in the farmers barn. A bag of insecticide was stored with the mealie meal and the youngster took some of the insecticide instead of the mealie meal. Members of the family died because of poisoning.
NOTICES AND SIGNS
Uniform SABS approved signs should be used. They consist of a specific shape, associated colour and a pictogram.
GREEN
Information (background used with white lettering)
Equipment start buttons
General locations
first aid
exit routes
rest areas
emergency showers
safety information
ORANGE
Indicates electrical utilities
electric service supply lines
electrical switchgear and fittings
Draws attention to dangerous moving machine parts
inside machine guards
parts capable of cutting, crushing or shearing shaft ends
exposed rotating machine parts
faces of gears
BLUE
Basic background colour used with white lettering or pictograms for mandatory purposes (PPE, etc.) e.g. noise area wear ear protection
FIRE FIGHTING INFO SIGNS
Location of fire Fire extinguisher Fire hose
fighting equipment
Fire hydrant Fire alarm Sprinkler stop
valve
Fire telephone Fire pump Location of
connection fire blanket
WARNING SIGNS
General warning Warning of Warning of
of danger fire hazard corrosion hazard
Warning of poisonous Warning of ionizing Warning of electrical
substance hazard radiation hazard shock hazard
Warning of suspended Warning of Warning of
loads hazard fragile roof workers overhead
Warning of slippery Warning of hazard of Warning of hazard
walking surface moving machinery of cold burns
Beware of forklifts Warning of hazard Warning of hazard of
of slippery stairs exposed high-voltage
equipment
PROHIBITORY SIGNS (DO NOT)
Smoking prohibited Fire and open flames
prohibited
Thoroughfare for Water as an
pedestrians prohibited extinguishing agent
prohibited
Drinking of this Use of compressed
water prohibited air to dust body
prohibited
Carrying of firearms Loose clothing, ties and
prohibited unconfined long hair
prohibited
Cameras prohibited Alcohol prohibited
MANDATORY SIGNS (MUST DO)
Eye protection Respiratory protection Hearing protection
shall be worn shall be worn shall be worn
Hand protection Foot and leg protection Foot protection against
against liquids shall be worn crushing shall be worn
Safety harness and Apron shall be worn Face protection
lifeline shall be worn shall be worn
Dust mask Keep area clean Screening to be used
shall be worn
GENERAL INFO SIGNS
First aid equipment General direction Direction to
escape route
Direction to Manned first aid Drinking water
escape route station
Traveling away Ladies toilets Gents toulets
Telephone Stairs going down Stairs going up
Eye wash Safety shower
COLOUR CODING, PLANT AND MACHINERY
For many years, in the absence of a standard colour code, many firms resorted to their own standards for colours for machinery, hazards, electrical equipment, pipe content, etc. This, at least provided a standard within an individual firm, but the time has arrived when it is highly desirable for the standardisation of colour coding throughout industry.
There is no doubt that uniformity of colour identification promotes greater safety, lessens the chance of error and warns against hazards caused by the mishandling of materials. The SABS, in conjunction with NOSA and other representatives from industry, have set out standards for colour identification. This NOSADATA has been prepared for the benefit of our members and is applicable to plant and machinery. Further NOSADATA setting colour standards for pipeline content, fire extinguishers, etc. will be issued as soon as these standards have been finalised.
The use of identification of hazardous machine parts, obstructions, pipes and services enables speedy recognition and, where intended, immediate warning of danger. Its value is obvious as a major contributing factor in the reduction of accidents and this value becomes of even greater importance where there is uniformity of colour marking among plants and organizations as it serves to eliminate confusion where workers transfer from one location or organization to another. Obvious too is its importance where the work force lacks a common language, as a standardized system has little or no need for words.
Education is an essential part of any system for giving information. On premises where colour identification is adopted, whether it be for safety, informatory or identification purposes, it is essential that a program of education be implemented. Such a program requires competent administration and should be of such a nature that no personnel are allowed to work in any area of a factory or plant until proved to be fully conversant with all relevant colour codes.
The marking of a physical hazard by a standard colour warning should never be accepted as a substitute for complete elimination of the hazard, wherever possible. It should supplement the proper guarding of machinery and other methods of eliminating hazardous conditions. Standard colour coding triggers off spontaneous action in an emergency.
COLOURS
All colours are based on, and should match SABS Code 1091. If improvement of conspicuity or emphasis of a specific colour is required, black or white may be used to provide contrast.
TABLE OF COLOURS
SABS 1091
Colour
Colour no.
Colour name
Blue
Green
Orange
Red
Yellow
F29
E14
B26
A11
B49
Cornflower blue
Emerald green
Light orange
Signal red
Golden yellow
Applicability of colours
Blue
Blue is a colour which should not be used on machinery. It is used as a colour code indicator on pipelines carrying drinkable water.
Green
Restrict the use of emerald green (when relevant, in conjunction with white lettering, stripes or edging, whichever provides the most effective contrast to the surroundings) to the identifications of:
the location of safety and first aid equipment
emergency exits and safety areas
informatory signs
starting devices on electrical equipment
miscellaneous safe conditions
AGRI-13-13000-FOU-13-00
Typical examples: (see also Fig. 1)
Location of safety and first aid equipment
location of first aid facilities, including stretchers
location of gas masks and rescue equipment
safety deluge showers or their location
Emergency exits and safety areas
emergency and other exits
areas of freedom from danger, e.g. safety refuges in quarries and steelworks (preferably shown by the block form of a shelter or shed)
Informatory signs
safety instruction signs
information signs
directional signs
Starting devices on electrical equipment
Starting devices on electrical equipment that is used for the control of machinery
Miscellaneous safe conditions
entrances
equipment stores and storage areas
locker rooms
offices
Parking areas
toilets
Orange
Restrict the use of light orange to the identification of:
electrical switchgear
electrical services
exposed and rotating machine parts
Typical examples: (see also Fig. 2)
Electrical switchgear
All electrical switchgear other than starting and stopping devices and emergency stop controls
Electrical services
All conduit and allied fittings
Exposed and rotating machine parts
the inside surfaces of chasings and guards of equipment and machinery that constitute a hazard (marked in such a way as to indicate when the casing or guard is not completely closed)
Note: the outside of such surfaces should be of a colour that provides an
effective contrast to light orange
the surfaces or protruding shafts, faces of exposed gear-wheels and any exposed rotating part of a machine
Red
Restrict the use of signal red (when relevant, in conjunction with white lettering, stripes or edging, whichever provides the most effective contrast to the surroundings) to the identification of:
danger
fire protection equipment and apparatus other than fire extinguishers. Fire extinguishers should be marked in accordance with the relevant part of this code (which will be added later)
stopping devices on electrical equipment that are used for the control of machinery
emergency devices for stopping machinery
Typical examples: (See also Fig. 3)
Danger
flashing red lights at rail crossings
danger signs
stores for explosives and other dangerous substances
barricades and obstructions prohibiting the passage of persons, vehicles or materials
Yellow
Restrict the use of golden yellow (when relevant, in conjunction with black) to the identification of:
objects and places where caution should be exercised
places where radiation hazards from radio-active materials exist
housekeeping markings
Typical examples: (See also Fig. 4)
Objects and places where caution should be exercised
industrial locomotives and other forms of mobile equipment that may constitute a hazard
barricades and temporary constructions that define the limits of an area in which caution should be exercised
low head room caused by the presence of structures, pipes, etc.
crane lifting hooks
changes in floor level and other similar tripping hazards
demarcation of No Parking areas on the floor below fire equipment and electrical switchgear panels
locations of explosive substances
Places where radiation hazards from radio-active materials exist
rooms and areas (outside or inside buildings) where radio-active materials are stored or handled or that have been contaminated with a radio-active material
burial grounds and storage areas for contaminated materials and equipment
disposal cans for contaminated materials
contaminated equipment that is not placed in special storage
Housekeeping markings
definition of walkways, etc.
demarcation of clear areas
If PPE is not the first choice or ideal method, is it then of any value in employee exposure protection?
PPE is very valuable as an interim measure i.e. where an exposure hazard has been identified, and engineering controls are not yet in place, or perhaps cannot ensure adequate protection due to circumstances beyond fixed reasonably practicable control.
What action is necessary when work needs to be carried out and is it not possible to engineer out personal exposure hazards?
The employer must identify the nature and extent of the problem. He then needs to obtain suitable protective equipment and ensure that it is issued to all staff after they have received education and training in its correct use, maintenance, cleaning and storage requirements.
What must employees do regarding PPE?
Every employee must use appropriate PPE correctly. Failure to do so may result in the employer being forced to take disciplinary steps. The Inspector may also decide to prosecute the employee and is he is found guilty of negligence of wilful misconduct he may be fined. Employees should be motivated to take responsibility for their own health and safety. This will be achieved through creating awareness and understanding of the principles, purpose and benefits of using all given PPE correctly at all times.
How do we know which type of equipment to use?
There is a large variety of equipment available. Once the hazard type and risk is known, someone should be appointed to be responsible for making sure that the correct equipment is in stock and used correctly.
SAPEMA (South African Protective Equipment Manufacturers Association) may be contacted for advice.
Who is responsible for training employees on PPE use?
The employer must see that employees receive appropriate training. Many suppliers of PPE run excellent programs on their own products. If this service is not available, training may be done by suitable in-house staff.
Does using PPE guarantee that there is no exposure to hazards?
Each type of PPE is designated with a specific purpose in mind. However, there are many factors which have an effect on its efficiency. These could include cleaning and storage practices; humidity levels, solvent exposure causing degeneration of certain materials, etc. The individual susceptibility of the person also needs to be taken into account.
Also, the way we wear PPE will have a bearing on how effective it is.
For example:
a hard hat is worn at the back of the head instead of centred over the crown, will not offer much protection if an object falls from above
ear plugs which are not correctly placed in the ear, will not reduce noise by the stated amount claimed by the manufacturer
respirators must have the right cartridge for the hazard. Users must also be trained to know when the cartridge is no longer effective and how to replace it
safety harnesses selection of correct type
What types of protective equipment are available?
Head
Hard hats, caps, crash helmets, hair nets
Eyes
Glasses, goggles, face shields, visors and strengthened prescription lenses
Ears
Earplugs (various types) and ear muffs
Lungs
Face masks, (application varies from nuisance dust to protection against certain substances. Selection is dependent on toxicity and type of substance)
respirators, the cartridges of which must be substance specific and compatible
air-lines which may include full air-line suits
self contained breathing apparatus sets for fire, rescue, or work in areas indicated by TLV-STEL or TLV-C measurements (Threshold Limited Value TLV)
Body
Aprons, suits, jackets, overalls
Legs
Spats and leggings, aprons
Hands
Gloves, mittens and gauntlets
Feet
Boots and shoes and foot protectors
EMERGENC ROUTES AND EQUIPMENT
Employees should be walked along the route, assembly points should be identified, and alarms demonstrated and understood.
POSTERS, BULLETINS, COMPETITIONS, VIDEOS, ETC.
Should be used on an continuing basis by the supervisor and Health and Safety Representative to explain or re-enforce programme requirements. All material should be discussed and explained. Posters should be rotated regularly.
INCIDENT RECALL
Recall and toolbox talks should be planned and carried out on a regular departmental basis.
5. COMPLIANCE WITH THE STANDARD AND PERSONAL PARTICIPATION
WORKPLACE RISK ASSESSMENT
The objective of this technique is:
To help employers and employees to assess risks in the workplace. It is aimed at practical workplace risk assessment
An assessment of risk is nothing more than a careful examination of what, in your work, could cause harm to people, so that you can weigh up whether you have taken enough precautions or should do more to prevent harm. The aim is make sure that no one gets hurt or becomes ill. Accidents and ill health can ruin lives, and affect your production too if output is lost, machinery is damaged, insurance costs increase, or you have to go to court.
Dont be put off by some of the words used in this guide:
i. Hazard means anything that can cause harm (e.g. chemicals, electricity, noise, etc.)
ii. Risk is the chance, great or small, that someone will be harmed by the hazard
The important things you need to decide are whether a hazard is significant, and whether you have it covered by satisfactory precautions so that the risk is small. You need to check this when you asses the risks. For instance, electricity can kill but the risk of doing so is an office environment is remote, provided live components are insulated and metal casings properly earthed.
HOW TO ASSESS THE RISK IN THE WORKPLACE?
Dont be overcomplicated in every department, the hazards are well known to supervisors but you will have to review the effectiveness of existing health and safety controls with all your workers. You may have already assessed some of them for example, if you use toxic or dangerous chemicals, you should already have made an assessment of the risks to health and precautions you need to take under the Regulations for Hazardous Chemical Substances, 25 August 1995. If so, you can consider them checked and write down if you are making a written assessment. For other hazards, you probably already know whether you have machinery that could cause harm or if there is an awkward entrance of travelling way where someone could be hurt. If so, check that you have taken what reasonable precautions you can to avoid injury.
If you are confident you understand the work, you can facilitate the assessment yourself. You could ask a responsible employee, safety representative or safety officer to help you. If you are not confident, get help from a competent source. But remember you are responsible for seeing it is adequately done.
STEP 1
LOOK FOR THE HAZARDS
If you are doing the assessment yourself, walk around your workplace and look afresh at what could reasonably be expected to cause harm. Ignore the trivial and concentrate only on significant hazards which could result in serious harm or affect several people. Ask your employees or their representatives what they think. They may have noticed things which are not immediately obvious. Manufacturers instructions or datasheets can also help you spot hazards and put risks in their true perspective. So can accidents and ill-health records.
STEP 2
DECIDE WHO MIGHT BE HARMED, AND HOW
Think about people who may not be in the workplace all the time, e.g. surveyors, visitors, contractors, maintenance personnel, etc. Include members of the public, or people you share your workplace with, if there is a chance they could be hurt by your activities.
STEP 3
EVALUATE THE RISKS ARISING FROM THE HAZARDS AND DECIDE WHETHER EXISTING PRECAUTIONS AND ADEQUATE OR MORE SHOULD BE DONE
Even after all precautions have been taken, usually some risk remains. What you have to decide for each significant hazard is whether this remaining risk is high, medium or low. First, ask yourself whether you have done all things that the law says you have got to do. For example, there are legal requirements on prevention of access to dangerous parts of machinery. Then ask yourself whether generally accepted industry standards are in place. But dont stop there think for yourself, because the law also says that you must do what is reasonably practicable to keep your workplace safe. Your real aim is to make all risks small by adding to your precautions if necessary.
If you find that something needs to be done, ask yourself:
(a) Can I get rid of the hazard altogether?
(b) If not, how can I control the risks so that harm is unlikely?
Only use personal protective equipment when there is nothing else that you can reasonably do.
If the work you do tends to vary a lot, or if you or your employees move from one site to another, select those hazards which you can reasonably foresee and assess the risks from them. After that, if you spot any unusual hazard when you get to a site, get information from others on site, and take what action seems necessary.
If you share a workplace, tell the other employers and self-employed people there about any risks your work could cause them, and what precautions you are taking. Also, think about the risks to your workforce from those who share your workplace.
STEP 4
RECORD YOUR FINDINGS
You should record the significant findings of your assessment. This means:
(1) writing down the more significant hazards and
(2) recording your most important conclusions for example, Electrical cable installation: insulation and suspension checked and found sound or Fumes from blasting: local exhaust ventilation provided and regularly checked. You should also inform your employees and their representatives about your findings.
There is no need to show how you did your assessment, provided you can show that:
A proper check was made by the team
You asked who might be affected
You dealt with all the obvious significant hazards, taking into account the number of people who could be involved
The precautions are reasonable and the remaining risk is low
Assessments need to be suitable and sufficient, not perfect. The real points are:
Are the precautions reasonable, and
Is there something to show that a proper check was made?
Keep the written document for future reference or use; it can help you if an inspector questions your precautions, or if you became involved in any action for civil liability. It can also remind you to keep an eye on particular matters. And it helps to show that you have done what the law requires. There is a form with this guide which you may find helpful but, by all means, produce your own form if it suits you better.
To make things simpler, you can refer to other documents, such as manuals, the arrangements in your health and safety policy statement, company rules, manufacturers instructions and your health and safety procedures. These may already list hazards and precautions. You dont need to repeat all that, and it is up to you whether you combine all the documents, or keep them separately.
STEP 5
REVIEW YOUR ASSESSMENT FROM TIME TO TIME AND REVISE IT IF NECESSARY
Sooner or later you will bring in new machines, substances and procedures, which could lead to new hazards. If there is any significant change, you should add to the assessment to take account from time to time. Dont amend your assessment for every trivial change, or still more, for each new job, but if a new job introduces significant new hazards of its own, you will want to consider them in their own right and do whether you need to keep the risks down.
WRITTEN SAFE WORK PROCEDURE
This is a systematic approach which enables us to identify all hazardous tasks and establish the likelihood of harm or loss arising out of or during the task. It means we can prioritise the action we need to take on an ongoing basis, until all tasks have been analyzed.
Once this analysis is completed, a second procedure is followed. This involves writing safe work procedures to be followed by anyone carrying out this job.
For companies who follow the ISO 9000 system, this means only having to review and add safety steps for all jobs which have already been analysed and documented. For other companies, who want to export to other countries, and intend going on to the ISO 9000 system, this is a major preliminary step in that direction, With or without incorporating the formal ISO 9000 system, this procedure will automatically improve quality control and maintain them on an ongoing basis health, safety and quality are inseparable.
An added benefit of Job Safety Analysis and written safe work procedures is that it gives us a ready tool which can be used for training new staff, checking on performance, investigation incidents and deviations, and giving recognition for good performance according to set standards as trained.
It also assists the operator to refresh his memory, when carrying out tasks which are not routine or are only required at intervals which may be far apart e.g. at shut-down.
What general precautionary measures would you take to protect employees and especially maintenance crews when working on mechanical and electrical equipment:
Never work on any live or moving equipment
All adjustments should only be undertaken by trained staff
Any hazardous tasks should be identified and covered by a work permit or written safe work procedure
Supervision / job observation should be on-going
Education and training should be given appropriate to tasks
Awareness and compliance of legislative requirements
Purchase specifications should ensure safety is incorporated at the design / manufacture stage
Inspect / check before commissioning
Formal hand-over should be completed after re-design, major repairs or new installations
Use of pirate parts must be checked to ensure load design capacities are appropriate and compatible
Safety devices should be part of regular scheduled checks
Never leave machines running while unattended
Wear appropriate PPE
No bypassing of safety devices
Use correct tools and procedures
Do not use hand to remove jammed particles
Isolation requirements must always be followed
All machinery and equipment should be on a preventative maintenance programme
INCIDENT / ACCIDENT REPORTING
There are two government departments which must be informed of certain incidents. There are specific forms and procedures which management must ensure are forwarded to the appropriate Regional Director: Occupational Health and Safety and the Compensation Commissioner of the Department of Labour. Someone should be appointed to ensure that this documentation is correctly completed at the Department of Labour.
The Regional Director at the Department of Labour must be told of any of the following by phone or fax, and this must be followed by the correct documentation being forwarded to him as soon as possible thereafter.
Unconsciousness
Any loss of a limb or part thereof
Death or likelihood of death
If a person is expected to be away from work, or on light duties for more that 14 days
Any broken bone
Any uncontrolled substance release
Any machine which runs out of control
Any parts of machinery which flies through the air
Any major hazard or major hazard installation risk
Any collapse of a building or structure
Does the company need to keep any other records of incidents?
Apart from copies of the above documents, the employer must carry out an investigation and keep record of findings and recommendations. The investigator should be trained in investigations. Management and the Health and Safety Representatives for the area should be involved, as well as the supervisor or manager. These reports must be discussed at the next committee meeting.
INTERNAL INCIDENT REPORTING
Should all incidents be investigated even if there is no loss or damage?
Incidents occur when something is wrong with the procedure, the system or the process otherwise the incident would not have happened. Therefore, even if there is no loss or damage this should be taken as a warning.
Investigations provide very important information so that the same or s similar situation does not happen again, where the outcome could be more serious.
The purpose of internal investigations is therefore to find the basic cause of the incident. Thereafter, steps can be taken to make sure that it does not happen again.
The steps in incident investigation are:
Train staff to carry out investigations
Appoint an investigator if appropriate
Inspect the scene and interview everyone involved or who witnessed it
Make notes and sketches and check systems
Identify the direct cause as well as the basic cause
Check the existing steps in the procedure
Evaluate and correct the standards
Review all other similar situations
Notify all necessary persons of recommendations
Record findings and report to Health and Safety Committee
Re-assess on a planned basis
Are statistics a valuable tool to prevent and anticipate future incidents?
Accurate records and an analysis of what type of incidents happen, at what time of the day or week, and how they happened are a most valuable source of information.
From these statistics we can identify exactly what training, education or procedures need to be changes. For example is the person new on that job; would an assistant be needed; is the pre-start check adequate, is the lighting adequate on night shift, etc.
Statistics, if correctly compiled and analysed, serve as a pro-active tool to identify areas which need attention and that should be included or provided for in the next financial years budget. (In critical instances immediate steps should be taken)
How can injury statistics be analyzed to pin-point problem areas?
Problem areas can be more easily pin-pointed if statistical information can be categorised to show trends or areas which need urgent or special attention.
The number of injuries to different body parts can be analyzed to show the prevalence of injuries to feet, hands, head, eyes, neck, backs, etc.
Information analyzed in this way can be presented in chart form at monthly Health and Safety Committee meetings.
6. OCCUPATIONAL HEALTH
Must every company employ Occupational Health Practitioners?
Management must identify the risks associated with the production process and then decide what systems and people they need to ensure that their workers occupational health and safety needs are catered for.
Is it a recommendation that all firms use the services of medically trained staff?
Again, this decision will need to be taken by each company according to the hazards associated with the nature of the tasks. Some points of consideration would include the following:
(a) Selection and Placement
It makes good sense for both the employee and the employer to ensure that the right person is employed for the job. One of the criteria is not to just to check on qualifications and experience, but also on physical and mental abilities to meet the demands of the job. Failure to do this, could result in the introduction of unsafe conditions.
(b) Medical Examinations
Man-job specifications and medical examinations form part of a thorough screenings process. These examinations can be done on site if facilities are available, or on a contractual basis by practitioners in private practice.
By choice, operations with high risks substances would benefit greatly by having suitable staff available on call, or on site. They should where practical, be appropriately trained in the specifics of occupational health and medicine. This training / experience should be appropriate to the risks associated with the many pertinent differences in approach to occupationally related health issues as opposed to general medicine. In the area of occupational health, the practitioner is dealing with a well person. The emphasis being on anticipation, identification and assessment of inherent risks i.e. preventative medicine.
Should all premises have trained First Aiders on site?
First aid facilities must be provided. Legislation lays down the requirements. Suitable supplies specific to the risks of the particular hazards staff may be exposed to must be available. Trained staff should be available to or stationed in areas so that in an emergency they can cope with any anticipated problems until outside help can take over.
Are Occupational Hygienists part of the health team?
Their knowledge of specific chemical and other health hazards, and the means of surveying and monitoring these are integral to accurately assessing hazards and their effects on the workforce.
This is a specialized field and abilities, qualifications and expertise should be verified in relation to each organizations hazards before appointing such a person.
7. ERGONOMICS
This is also an important health factor and someone should be appointed to look at the different areas, which can effect an employees well-being and productivity in the long term.
Ergonomics incorporates many areas which are best addressed in more detail than there is time for during this course. A separate course is available to cater for its many facets.
What is Ergonomics?
This field is also known as Human Factors Engineering.
Areas include:
Ventilation, temperatures, air movement, extraction of substances
Lighting
Noise
Work station design
Instrumentation controls and design
Muscular strains and stresses
Manual handling
Vibration
What is the purpose of practising ergonomics?
The implementation of a sound ergonomic program results in:
Better utilization of worker skills
Reduction of fatigue
Reduction of injuries and associated claims
Reduction of absenteeism
Increased output
Increased worker morale
Increased job satisfaction
Increased productivity
Must ergonomics be carries out by specialists?
With a little training, persons with appropriate backgrounds (e.g. engineers, or persons with a physiological background) can be trained to carry out many cost effective productive programs, for initial identification and improvements of conditions.
Thereafter, more specialized persons (e.g. design engineers and occupational hygienists) can be called in to further assist and refine programs.
Are ergonomic studies and programmes costly to implement?
In many instances they cost little or next to nothing. All that is required is a change of position, screening off glare from lights, or raising or lowering a work surface, to achieve very quick and measurable effects.
MANUAL HANDLING
Back injuries account for the highest number of employee injuries annually.
Employees should be taught correct techniques. They must also be aware that any back pain should be reported immediately, even if not severe, to avoid long term, or permanent damage
Load size and shape should be assessed and the method determined to handle it appropriately i.e. by hand or mechanically
Work station design should be assessed and wide range lifting be engineered out of the process
Large load, or high volume manual lifting per shift should be avoided.
Lifting and twisting must be avoided. Lift, move feet, face drop area and lower
Objects required to be lifted repetitively should be located in the reach area between shoulder and knee height
Man-job specifications must be utilized for employees doing manual lifting tasks
Appropriate PPE (e.g. gloves, hard hats) should be provided where indicated
Pushing and pulling loads can also place excessive strain on the back, and correct techniques and equipment should be used after training has been given
Drop and pick-up areas should be designed to accommodate unrestricted work flow without excessive handling
8. MACHINE GUARDS
Why is machine guarding important?
Injuries caused by machines, are usually severe and permanent
Machine guarding can help prevent incidents and injuries
Dangers can often be reduced or removed altogether by mechanical safeguards and better machine design or construction. On the other hand, safe human habits and practices are difficult to cultivate and maintain. Furthermore, mechanical improvements are usually permanent.
What are the three basic types of guards?
Fixed guards
These are usually used on transmission machinery. They do not move with each operation. They are also used on power presses and are adjusted to accommodate various different sizes of work and are fixed into place after adjustment.
Interlocking guards
This type of operation prevents the operation of the controls which set the machine in operation until the guard is moved into place. This means that operators cannot place their hands in the machine when it is in motion. These guards may be operated electronically, mechanically, pneumatically, or by a combination of all three.
Automatic guards
This type prevents the operator from coming into contact with dangerous parts of the machine while it is moving. Other automatic guards stop machines when there is danger, for example an electronic beam system which stops the machine as soon as the beam is broken by any part of the body or by an object.
What characteristics should a good guard have?
Provide maximum positive protection
Block access to the danger zone during operation
Corrosion and fire resistant and easily repairable
Hazards such as splinters and nip points should not be created by the guard
It should be a permanent part of the machinery without weakening its structure
Efficient operation of the machine should not be affected by the guard
It should be strong enough to withstand normal wear and tear
Where the guard is bulky, hinging should be considered to facilitate the servicing and repair of belts or gears, etc.
Why are treadle or stirrup guards essential for foot operated machines?
Foot treadle or stirrup guards prevent the accidental operation of punch presses and other foot-operated equipment from objects falling on the treadle or by the operator unintentionally stepping on it.
How does a phote-electric device operate?
It is an automatic stop device which makes use of light beams or light curtains. As soon as the light beam is broken it stops the machine at whatever stage of the operation is it in at the time.
9. LOCK-OUTS
Unexpected or uncontrolled operation may result in death or serious injury.
Policy and procedures should be established and training given
Principles include:
Each appropriate individual has a copy and signs for receipt and training regarding this procedure
All areas / tasks should be identified in writing
- Electrical energy sources
- Mechanical energy sources (e.g. steam, hydraulics, air)
- Chemical lines and piping
- Confined spaces
- Shut down procedures
- Unplanned downtime procedures
- Identify all energy sources to any one piece of equipment or plane
One lock issued per person
Locks should be numbered and their issue documented
Duplicate key to be locked away in responsible persons care. Only he may unlock in an emergency / key loss and signs for doing this
Issue Work permits where appropriate
Lock-out may not be substituted by tag-out
All equipment must be able to accommodate locks
No exchanging of locks allowed
Gang locks to be used when more than one person is assigned to one piece of equipment, with each worker locking out individually
Test electrical supply to zero potential before starting repairs / adjustments
Release stores / residual energy in supply lines
Notify affected persons / departments that line is going down
On completion, test safe, remove locks and notify operator(s) and supervisor that energy and lines are restored
10. LADDERS AND SCAFFOLD
What are the basic rules for the safe use of ladders?
Always avoid bringing metal or alloy ladders into contact with electrical supply sources
Place the ladder so that its feet are a quarter of its length to the top support from the surface which it is resting against
Unless the ladder is secured at the top, it should always be held in position by another person as long as someone is standing on it
Wherever possible it should extend 1 meter of at least three rungs above its top support
Ladders should be inspected at frequent intervals. Defects should be repaired immediately or the ladder replaced
Keep ladders clean and do not paint them, as this hides any defects
Do not leave ladders on wet ground or exposed to the weather
Ladders lying on floors may cause employees to trip or fall, or they may be run over by vehicles and damaged
Do not use ladders horizontally as walkways or scaffolds
Tools and equipment should be hauled up by rope
Never leave a ladder standing where it may fall over
Never place a ladder in front of an unlocked doorway
Ladders should be fitted with non-slip feet
Store ladders in a cool dry place, either lying on their side, or supported on hooks against a wall, this will help to avoid warping of wooden ladders and makes it easier to check its length
All ladders should be identified and entered on a register. Checks should be regular and any defects recorded and reported
Only one person should be on a ladder at any one time, and both hands should be used for climbing
Do not leave any tools on the ladder
Use the correct ladder for the job
What are the most important safety requirements to be considered with regard to scaffold platforms and supports?
Legislation in regard to scaffolding regulations is extensive and should be referred to for detailed information. The following indicate some general principles in regard to erecting and using scaffolding.
Scaffold must be erected, changed, broken down and stored only under the supervision of a competent person
Inspection by a competent person must be carried out after erection and thereafter once a week, as well as after any bad weather
Working platforms must be kept clean and all boards are to be secured and flush
Asbestos
Dusts
Lead laden combustion fumes or leachate from dumps
Carbon monoxide generated from fuel consumption
Acid or alkali dumps into water drainage systems as well as any toxic chemicals or carcinogenic substances which may not, in themselves be toxic, but pose a threat to the ecological balance and systems (e.g. insecticides, pesticides, organic phosphates, etc,)
Carbon products from various combustion processes, (power stations, boilers, etc.)
Benzene, petroleum products leaching through ground soils or into water supplies (often from poorly controlled run-off)
Formaldehydes (especially when they are incinerated)
Packaging products which contain PVCs etc. or other materials which are not biodegradable
What are the major concerns we are faced with in South Africa in regard to pollution?
Of major importance and concern is the amount of overall general waste in generated in this country where our specialised disposal and treatment facilities are minimal, and our infrastructure makes effective handling difficult and costly.
South Africa generates an average of 20kg of waste per person per day. Our geographic distance are vast and our comparatively small population cannot financially support the type of high-tech waste disposal and/or treatment operations which are viable in overseas industrialized countries.
How can industry have a positive impact on pollution control measurements?
We need to follow a systematic approach in regard to containment, reduction and disposal approaches.
Identify the risk substances and/or processes
Formulate an Environmental Engineering Pollution Control Policy
Establish a programme
Appoint a co-ordinator and provide adequate education, training and other necessary facilities as indicated by demands
Prioritize critical issues and establish an action plan
Educate and train:
- employees
- users
- intermediate agents (e.g. transportation agents)
- appropriate support services (Fire, Municipal, Civil Defence, Air Traffic stations, etc)
What type of issues should an APC Policy address?
Any areas where there is a responsibility for generating or using any substances which give rise to emissions, and eliminate them or handle them at the source
Develop products which have minimal environmental affects
Conserve natural resources (re-design, re-cycle, re-use)
Comply with local legislation and work towards international standards
Share knowledge and if appropriate resources with other companies who generate like waste
Educate employees and the community
11. OFFENCES AND PENALTIES
Any person who:
tampers with or misuses any safety equipment installed or provided to any person by an employer or used;
fails to use any safety equipment at a workplace or in the course of his employment or in connection with the use of plant or machinery, which was provided to him by an employer or such a user;
wilfully or recklessly does anything at a workplace or in connection with the use of plant or machinery which threatens the health or safety of any person
shall be guilty of an offence and on conviction be liable to a fine up to R50 000 or to imprisonment for up to one year or both.
Any employer who does or omits to do an act, thereby causing any person to be injured at a workplace, or, in the case of a person employed by him, to be injured at any place in the course of his employment, or any user who does or omits to do an act in connection with the use of plant or machinery, thereby causing any person to be injured, shall be guilty of an offence if that employer or user would in respect of that act or omission caused the death of the person, irrespective of whether or not the injury could have led to the death of the person, and on conviction be liable to a fine up to R100 000 or to imprisonment for up to two years, or both.
PROCEDURE WHEN HEALTH AND SAFETY IS ENDANGERED
WORKER HAS REASON TO BELIEVE WORK IS LIKELY TO ENDANGER HIMSELF OR ANOTHER PERSON
SUPERVISOR
Investigates forthwith in presence of the worker and an H & S Committee member
WORKER
Promptly reports circumstance to supervisor, remains in safe place
Agreement and/or resolution
DISAGREEMENT:
Worker continues to refuse:
Worker has reasonable grounds to believe work still likely to endanger himself or another worker
RETURN TO WORK
SUPERVISOR:
Notifies plant risk control manager
Disputed equipment or workplace not to be used pending investigation and decision
WORKER
Remains in safe place unless assigned to reasonable alternative work or given other directions pending investigation and decision
PLANT RISK CONTROL MANAGER:
Investigates in presence of employee, supervisor and employee representative
RISK CONTROL
MANAGER
Gives decision to employee and supervisor as soon as practicable
CORRECT PROBLEM
RETURN TO WORK
SAFETY, HEALTH AND ENVIRONMENTAL ATTENDANCE REGISTER
Employee Name:___________________________Company Number:______________________________
Occupation:_______________________________Business Unit:__________________________________
ITEMS COVERED DURING INDUCTION
EMPLOYEE INITIAL
ITEMS COVERED DURING INDUCTION
EMPLOYEE INITIAL
Introduction to the Occupational Health and Safety Act
Know your QFC (Quality Focus Centre)
Know the duties of the Employers to the employees
Know your fire equipment
Know the duties of the employees at work
How to report a fire
Know your Health and Safety Representatives
Environmental policy
Know the functions of the Health and Safety Representatives
Clock in/out procedure
Know your Health and Safety Committee
Know the danger areas (noise zones, etc.)
Know the functions of the Health and Safety Committee
Know the area of smoking / fire requirements
Know the five practical steps to workplace risk assessment
Understand all signs and notices
Know your written Health and Safety work procedures
Know your information boards
Know the definition of an incident / accident
Understand your colour coding
Understand the eleven points of unsafe practices
Understand good housekeeping
Understand the eleven points of unsafe conditions
How to obtain Personal Protective Equipment
Know your first aider
How to use and maintain Personal Protective Equipment
How to report an incident / accident (Ref to duties of employee)
Understand the offences and penalties
Compensation for injuries
Understand T.Q.M. grading board
Know your fire team members
Use of refuse bins
Know your fire prevention programme
Understand equipment inspection
Know your emergency evacuation procedure
Lock-outs and machine guarding
PLANNED JOB OBSERVATION
MONDI CARTONBOARD
Department: ______________________Date: ________________________
Task: _______________________________________________________________
Observer: ___________________________________________________________
Employee Name: _____________________________________________________
REASON FOR JOB OBSERVATION
New worker
Accident repeater
Ergonomic factor
Risk taker
Unusual job
Environmental
Poor performer
High risk job
TYPE OF DEVIATION
FULL DESCRIPTION
ACTION TAKEN
RECOMMENDATIONS
Transfer employee
Induction training
Discipline
Health and Safety Training
Provide Protection
Environmental Impairment Programme
Training on safe work procedures
SIGNATURE OF SUPERVISOR________________________DATE:_________________
SIGNATURE OF EMPLOYEE:_________________________DATE:_________________
INDUCTION QUESTIONNAIRE
Name: _____________________________________________________ Coy no: ________
1. What is the law that governs the health and safety of the workplace?
__________________________________________________________________________
2. What are the law regarding health and safety in connection with machinery
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
3. How are you responsible for the safety of others at the workplace?
____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
4. What are the consequences of any person if injured while ignoring or deviated from the set health and safety standard?
____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
5. What is the definition of the word safety?
____________________________________________________________________________________________________________________________________________________
6. Whose responsibility is safety?
____________________________________________________________________________________________________________________________________________________
7. What is every employees responsibility with regard to unsafe practices or conditions?
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
8. When should an incident / accident be reported?
____________________________________________________________________________________________________________________________________________________
9. Who are the Safety, Health and Environmental Representative of your department?
__________________________________________________________________________
10. What is the function of the Safety, Health and Environmental Representative?
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
11. What is the lock out procedure?
____________________________________________________________________________________________________________________________________________________
12. What is the purpose of the lock out procedure?
____________________________________________________________________________________________________________________________________________________
13. Who is authorised to isolate / de-isolate electrical driven machinery?
____________________________________________________________________________________________________________________________________________________
14. What is the equipment in the plant of which an operating license is required?
__________________________________________________________________________
15. What should you do when observing fire or bomb threat?
____________________________________________________________________________________________________________________________________________________
16. What should you do on hearing a fire alarm?
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
17. What type of fire extinguisher should be used to extinguish fire when electrical equipment is involved?
____________________________________________________________________________________________________________________________________________________
18. Briefly explain the term Multi-skilled
____________________________________________________________________________________________________________________________________________________
19. Name at least four places where smoking is strictly prohibited
(a) _______________________________________________________________________
(b) _______________________________________________________________________
(c) _______________________________________________________________________
(d) _______________________________________________________________________
20. Briefly explain the term Housekeeping
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
21. What do the following signs signify?
_______________________ _________________________
________________________________________________
_________________________________________________
Signature: __________________________________Date: ____/____/________
WORKSHOP 1
We have seen what the general duties of employers, the general duties of employees and the duties of employers towards their Health and Safety Representative are. List five general duties of employers and five general duties of employees and then discuss briefly how the health and safety standard in the workplace will improve if both parties conform to these duties laid upon them.
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Environmental care and Waste disposal
Use of tools and Tool Care
Hand Tools - Pliers and Wrenches
General
Use tools for their intended purpose. Don't use pliers as wrenches. Don't use wrenches as hammers.
Wherever possible, don't expose tools to extremes of heat and cold. Metal will lose its temper and get brittle.
Don't extend the handles of tools with sleeves or cheater bars for more leverage and power.
Don't mistake cushion grips with insulated handles. Cushion grips are for comfort only. Insulated handles are for electrical shock protection.
Don't hammer on the handles of wrenches or pliers to gain more force. The tool could bend, break, or fly off and hit you or someone else.
Pliers
Use pliers with enough space between the handles to keep palm and fingers from being pinched.
Pull on pliers - don't push.
Oil regularly. All it takes is a drop of oil on the hinge.
Cut at right angles. Don't rock cutting edges from side to side or bend wire back and forth. That means your pliers are too small or too dull for the job.
Don't use pliers to turn nuts and bolts. The jaws will slip and damage corners and edges of nuts and bolt heads.
Wrenches
Replace damaged wrenches. Straightening a bent wrench only weakens it.
Pull on a wrench - don't push.
Be prepared in case the wrench slips. Make sure your footing is solid, your stance balanced and your hands clear.
With adjustable wrenches, put pressure on the permanent jaw, not the movable jaw.
Use the right wrench for the job. Don't use pipe wrenches on nuts or bolts. Don't use adjustable wrenches on pipe.
On adjustable wrenches, inspect knurl, jaw and pin for wear.
Safe Work Practices
Safe work practices are ways of controlling hazards and doing jobs with a minimum of risk to people and property. To reduce risks, an organization must have a set of safe work practices. These must be developed to fit the particular company.
Management must understand and fully endorse these safe work practices, and ensure that:
safe work practices are in writing
all employees understand the safe work practices that apply to them
all equipment and management support to permit compliance are available
supervisors ensure that all safe work practices are followed
safe work practices are reviewed annually and recorded
Use of Portable Grinders
Abrasive wheels can cause severe injury. Proper storage, use and maintenance of wheels must be observed.
Familiarize yourself with the grinder operation before starting work.
Ensure proper guards are in place and that safety glasses, face shields, gloves